Wall Mountable Holder System

ABSTRACT

A substrate-mountable holder system, comprising a base having a hook, a first front surface and a second front surface with a groove therebetween, wherein the groove includes a rearward facing face having a step. The system also includes a second portion for operatively engaging the first portion, the second portion including a tongue component positionable within the groove, wherein the tongue component includes a forward facing face having a step. The base also may include at least one notch extending inward from the rear surface, the notch having a first surface at a first depth relative to a rear surface of the base and a second surface at a second, deeper depth relative to the rear surface, and the cover may have at least one ear for releasably engaging the at least one notch.

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/395,286, filed on Feb. 27, 2009, of U.S. patent applicationSer. No. 12/610,946, filed on Nov. 2, 2009, and of U.S. patentapplication Ser. No. 12/697,868, filed on Feb. 1, 2010.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a wall mountable holder, mountablein a friable substrate such as drywall or on a semi-rigid material suchas a hollow-core door, for holding objects such as household items,e.g., bags, robes, coats, etc.

2. Description of the Related Art

Wall mountable holders come in several varieties for differentapplications. One type of holder has an integrated screw protruding froma rear surface, the screw having relatively small root and majordiameters. To install this holder, a user rotates the entire holder,driving the fastener into the mounting substrate. Unfortunately, whencompletely installed, the fastener may not be oriented properly and mayrequire a partial turn to accomplish this orientation, either backingthe holder out of the substrate, potentially weakening the holdingstrength of the holder, or embedding a non-threaded portion into thesubstrate, increasing stress on the holder and potentially causing theholder to fracture, deform or otherwise fail during installation. Inaddition, these holders generally are designed for use in rigidsubstrates such as exposed studs and perform poorly in friablesubstrates.

A second type of holder may include a base plate that is held in placeon a wall while one or more sheet metal-type fasteners are driven intothe substrate. As with the first variety of holder described above, thissecond type of holder often is not suitable for use in semi-rigid,friable or hollow substrate applications.

These first and second types of holders may be located so that thethreaded portion or the fasteners, respectively, are located at a pointoverlying a stud. If long enough, these threaded portions may embed inthe stud, thereby increasing the holder's holding strength. Toaccomplish this goal, however, pre-drilling into the stud may berequired. In each case then, additional planning, tools and time wouldbe required. In addition, some holders require one or more screws to bedriven, but unless pilot holes are positioned, sized and pre-drilledwith great care, efforts to drive screws can result in stripping of thedrywall, thereby reducing holding strength.

A third type of holder is a generally one-piece design and relies on anadhesive backing to keep the holder in place. These holders may be usedin a variety of locations, but their holding strength may besignificantly less than that of the holders described above, even infriable substrate applications, due to the low holding strength of theadhesive. Additionally, adhesive installations require wall preparationand waiting time before mounting is complete and objects can besupported by the holder.

What is needed is a holder mountable to a friable substrate that may beinstalled easily for increased pullout resistance and load capacity.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention, a substrate-mountable holder system,comprising: a first portion comprising a base having a first frontsurface and a second front surface, a rear surface, a top and a bottom,a hook extending from proximate the bottom, a lobe extending rearwardlyfrom a rear surface proximate the top, a pad extending rearwardly fromthe rear surface, an opening for receiving an anchor extending from thefirst front surface to the rear surface, the opening between the lobeand the pad, and at least one detent; and a second portion foroperatively engaging the first portion, the second portion comprising atleast one second detent for releasably engaging the at least one detent.The system may include a self-drilling drywall anchor having a bore anda fastener for operatively engaging the first portion and the bore.

The first portion lobe may include a barb extending rearwardly from arear surface of the lobe. In addition, the first portion may include aface angled with respect to the top and the first front surfaceproximate the top, and the second portion may include a cam member on arear surface for engaging the face. Moreover, the first portion mayinclude a tang proximate the bottom of the first portion, wherein thetang has a base located in a recess in the rear surface and the firstportion may have a channel extending inward from the rear surface orfrom the recess.

In another aspect of the invention, a substrate-mountable holder system,comprising: a first portion comprising a base having a first frontsurface and a second front surface, a rear surface, a top and a bottom,a hook extending from proximate the bottom, a channel between the firstand second front surfaces, and a plurality of detents within thechannel; and a second portion for operatively engaging the firstportion, the second portion having a plurality of tongue portions forengaging the channel and a plurality of detents on the tongue portionsfor engaging the plurality of detents within the channel. The firstportion may have a lobe extending rearward from proximate the top and apad spaced from the lobe and also extending rearward. The lobe mayextend rearward a greater distance than the pad, and the pad may taperinward from a top towards a bottom. The plurality of detents on thefirst portion may be female detents, while the plurality of detents onthe second portion may be male detents that taper inwards towards thetongue portions from a top towards a bottom.

In still another aspect of the invention, a substrate-mountable holdersystem, comprising: a first portion comprising a base having a firstfront surface and a second front surface, a rear surface, a top and abottom, a hook extending from proximate the bottom, a lobe extendingrearward from the rear surface proximate the top, a pad extendingrearwardly from the rear surface, an opening for receiving an anchorextending from the first front surface to the rear surface, the openingbetween the lobe and the pad; a second portion or cover for releasablyengaging the first portion, the second portion having a rear edge; and aself-drilling drywall anchor having a bore, and a fastener foroperatively engaging the first portion and the bore; wherein at least aportion of the rear edge of the cover is spaced from the substrate and abottom of the rear edge engages the substrate when the first portion isinstalled on the substrate and the second portion engages the firstportion.

The holder system further may include a plurality of interfacing detentson the first and second portions. In addition, the second portion mayinclude a barb extending rearwardly from the lobe and/or at least onetang extending rearwardly from the rear surface. The tang may have abase within a recess on the rear surface and may be frangible proximateits base so that if not broken cleanly, preferably any remaining tangportion does not extend beyond the recess.

In yet another aspect of the invention, a substrate-mountable holdersystem, comprising: a first portion comprising a base having a firstfront surface and a second front surface, a rear surface, a top and abottom, a hook extending from proximate the bottom, a lobe extendingrearwardly from a rear surface proximate the top, a pad extendingrearwardly from the rear surface, an opening for receiving an anchorextending from the first front surface to the rear surface, the openingbetween the lobe and the pad; and a second portion for operativelyengaging the first portion; wherein the first portion and the secondportion each include at least one, and preferably a plurality of,interfacing protrusions and indentations for engaging the second portionwith the first portion. Each of the protrusions and indentations on thefirst and second portions may be proximate the bottom of theirrespective portions. The system further may include a self-drillingdrywall anchor having a bore, and a fastener for operatively engagingthe first portion and the bore.

In still another aspect of the invention, a substrate-mountable holdersystem may comprise a first portion comprising a base having a firstfront surface and a second front surface, a rear surface, a top and abottom, a hook extending from proximate the bottom, and a channelbetween the first and second front surfaces; and a second portion foroperatively engaging the first portion, the second portion having aplurality of tongue portions for engaging the channel; wherein the firstand second portions each include a set of releasably interfacingprotrusions and indentations. The first portion may include an openingfor receiving a fastener, wherein the pad is substantially aligned withan edge of the opening or wherein an upper edge of the pad is spacedfrom the center by a distance less than the radius of the head of ananchor. In addition, the protrusion on the first portion may be largerthan the protrusion on the second portion.

In a further aspect of the invention, a substrate-mountable holdersystem, comprising: a first portion comprising a base having a firstfront surface and a second front surface with a channel therebetween, arear surface, a top and a bottom, a hook extending from proximate thebottom, a lobe extending rearward from the rear surface proximate thetop, an opening for receiving an anchor extending from the first frontsurface to the rear surface, a pad extending rearwardly from the rearsurface substantially adjacent to the opening; a second portion forreleasably engaging the first portion, the second portion having aplurality of tongue portions extending downward for engaging thechannel, wherein the tongue portions extend from rails along a back ofthe second portion; and a self-drilling drywall anchor having a bore,and a fastener for operatively engaging the first portion and the bore.Additionally, each of the rails may extend substantially a length of thesecond portion, and each of the rails may include a channel alongsubstantially a length of the rail. The first portion may include aplurality of guides and at least one notch, and the second portion mayinclude at least one respective ear for guiding and connecting thesecond portion to the first portion.

In still another embodiment, a substrate-mountable holder system mayinclude: a first portion comprising a base having an opening forreceiving a fastener to mount the base to a substrate, a hook, a firstfront surface and a second front surface with a groove therebetween,wherein the groove includes a rearward facing face having a step; and asecond portion for operatively engaging the first portion, the secondportion including a tongue component positionable within the groove,wherein the tongue component includes a forward facing face having astep.

The groove may include a ramp surface between the step on the firstportion and a bottom of the groove. Similarly, the tongue component mayinclude an angled face between the step on the second portion and abottom of the tongue component. In addition, the step on the secondportion may include a radiused edge and also may have a horizontallength greater than a horizontal length of the step on the firstportion, but both steps may have generally equal heights.

The second portion may include an ear and the first portion may have anotch configured to receive the ear. The notch may extend downward froma top of the first portion and may have a height such that the earremains disposed within the notch after the tongue component clears therearward facing face of the groove. Additionally, the notch may includea first notch surface at a first depth relative to a back of the baseand a second notch surface at a second, deeper depth relative to theback.

In yet another embodiment, a substrate mountable holder system mayinclude: a base having first and second front surfaces, a rear surface,a top and a bottom, one or more openings for receiving a fastener, ahook extending from proximate the bottom, and a channel between thefirst and second front surfaces. The base also may include at least onenotch extending inward from the rear surface, the notch having a firstsurface at a first depth relative to a rear surface of the base and asecond surface at a second, deeper depth relative to the rear surface.The holder system also may include a cover having at least one ear forreleasably engaging the at least one notch and one or more guidesextending inward from a side of the cover. When the cover is coupled tothe base, at least a portion of the ear may be disposed along the firstsurface of the notch.

One of the guides may form a lower portion of one of the ears on eachside of the cover. Additionally, one of the guides may extend inward asmaller amount than another one of the guides so as to accommodate awider portion of the base, e.g., a portion beneath the notches.

A plurality of different covers may be used with the base, includinggenerally flat-faced covers and covers with one or more hooks extendingaway from the front surface. In the latter case, at least one of theears may extend between about ⅓ and about ½ the height of the cover. Thenotch may include an inset portion proximate the top, the inset portionextending inwards from the second surface and having a depthsubstantially equal to the first surface. The at least one ear may beconfigured to be received in the notch at substantially all of the insetportion and a majority of the first surface, and at least one of thebase and cover may be substantially symmetrical.

These and other features and advantages are evident from the followingdescription of the present invention, with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective, partial cross-sectional view of one embodimentof a holder system mountable to a variety of substrates for holding anobject.

FIG. 2A is a perspective, exploded view of the base and cover portionsof one embodiment of a holder system mountable to a variety ofsubstrates for holding an object.

FIG. 2B is a perspective, exploded view of the holder system of FIG. 2A.

FIG. 2C is a partial section view of the intersection of base and coverportions of the holder system of FIG. 2A.

FIG. 3A is another perspective, exploded view of the base and coverportions of the holder system of FIG. 2A.

FIG. 3B is another perspective, exploded view of the base and coverportions of the holder system of FIG. 2A.

FIG. 3C is a detail view of Section 3C in FIG. 3A.

FIG. 3D is a detail view of Section 3D in FIG. 3B.

FIG. 4 is a partial section view of the base of the holder system ofFIG. 2A.

FIG. 5 is a partial perspective view of a rear portion of the base ofthe holder system of FIG. 2A.

FIG. 6 is a partial perspective view of another embodiment of a base.

FIG. 7A is a side view at one stage during the installation of the coverportion of the holder system of FIG. 2A.

FIG. 7B is a detail view of Section 7B in FIG. 7A.

FIG. 8A is a side view at a second stage during the installation of thecover portion of the holder system of FIG. 2A.

FIG. 8B is a detail view of Section 8B in FIG. 8A.

FIG. 8C is a detail view of the top portion of FIG. 8A.

FIG. 9 is a perspective, exploded view of another embodiment of a holdersystem mountable to a variety of substrates for holding an object.

FIG. 10 is a side view of the base portion of FIG. 9.

FIG. 11 is a rear, perspective view of the base portion of FIG. 9.

FIG. 12 is a perspective, exploded view of yet another embodiment of aholder system mountable to a variety of substrates for holding anobject.

FIG. 13 is a side view of the base portion of FIG. 12.

FIG. 14 is a rear, perspective view of the base portion of FIG. 12.

FIG. 15 is a side view of one type of self-drilling anchor used in aholder system mountable to a variety of substrates for holding anobject.

FIG. 16 is a second side view of the anchor of FIG. 15, rotated 90degrees from FIG. 15.

FIG. 17 is a rear, partially exploded view of still another embodimentof a holder system mountable to a variety of substrates for holding anobject.

FIG. 18 is a detail view of section 18 in FIG. 17.

FIG. 19 is a side, perspective view of the base portion of FIG. 17.

FIG. 20 is a rear, perspective view of the cover portion of FIG. 17.

FIG. 21 is a front, perspective view of another embodiment of a baseportion.

FIG. 22 is a rear, perspective view of the base portion of FIG. 21coupled to another embodiment of a cover portion.

FIG. 23 is a rear, perspective view of the base portion of FIG. 21coupled to still another embodiment of a cover portion.

FIG. 24 is a front view of an assembled holder system.

FIG. 25 is a section view through line 25-25 in FIG. 24.

FIG. 25A is a detail view of detail A in FIG. 25.

DETAILED DESCRIPTION

In one embodiment, a hook system 10 for mounting to a substrate 2 mayinclude a first portion 20, a second portion or cover 60, an anchor 4and fastener 6, wherein the first and second portions may besubstantially symmetrical about an axis or plane 8. The hook system 10may include at least one set of interfacing male and female detents onthe first and second portions to hold those portions together.

In addition, as seen in FIG. 1, first portion 20 may include a raised,upper lobe 52 proximate its top 26 and a stopper pad 59 on its backportion 32. When installed against a substrate 2, first portion 20 maybow in the area around fastener opening 46. Upper lobe 52 and stopperpad 59 may limit the amount of bowing so that detents 31, 33 on firstportion 20 remain in a generally predictable, generally constantlocation relative to substrate 2. In another embodiment, upper lobe 52may include a barb that may embed in substrate to prevent rotation ortranslation of first portion 20 relative to substrate 2. Alternatively,or in addition, back 32 may include one or more tangs 56, 57 to furtherprevent rotation of first portion 20 relative to substrate.

First Portion

First portion 20 may include a hook 22 extending from a base 24, thebase 24 having a top 26, bottom 28, a first front surface 30, secondfront surface 36, rear surface 32 and sides 34. First front surface 30and second front surface 36 may be generally planar and generallyparallel to substrate 2. In addition, base 24 may be generally oblongand may have a height greater than a maximum width. Moreover, firstfront surface 30 may have an opening 46 for receiving fastener 6.

Hook 22 may extend from bottom 28 of base 24 to form a throat having awidth T between hook 22 and base 24. Bottom of hook 22 may extendgenerally perpendicular to rear surface 32 of base 24 and then turn toextend outward and upward. Similarly, bottom 38 of throat may rolldownward and outward to allow for a larger spacing between hook 22 andbase 24 while disguising the size of the opening, making hook 22 appearsmaller. Hook 22 may extend to an enlarged end or bulb 40 that may bewider than a portion of hook 22 proximate bulb 40 in order to helpretain objects on hook 22 and prevent them from becoming dislodgedeasily. To further aid in this function, hook 22 may have a button 42protruding from an inward-facing surface of bulb 40, and button 42 maybe shaped to retain items hung on hook, e.g., by having a broad bottomsubstantially perpendicular to mounting surface against which items maybear.

Turning to FIGS. 2A-2B, first portion 20 may have a groove 44 betweenfirst front surface 30 and second front surface 36. Groove 44 may begenerally perpendicular to both surfaces and may extend along a portionof a perimeter of second front surface 36 and substantially across awidth of base 24. The portion of the perimeter of second front surface36 that generally tracks groove 44 may be parabolic or bell shaped,coming to a rounded apex at top 37 of second front surface 36.

First front surface 30 may have an opening 46 for receiving fastener 6.Opening 46 may be spaced between top 37 of second front surface 36 andtop 26 of first front surface 30 and may be generally aligned on axis 8.Opening 46 may have a recess 48 for receiving a head of fastener 6 sothat the underside of the head preferably lays recessed with respect tofirst front surface 30, allowing for better engagement between firstportion 20 and cover 60. Alternatively, head of fastener 6 may protrudeslightly from first front surface 30, with recess 48 allowing for thehead of fastener 6 to be at least partially recessed relative to thefirst front surface. Shear loading on hook 22 may be preferable than abending moment component of an applied load since friable substrateshave larger shear loading capacities as compared to bending momentcapacities, and higher shear loading may be accomplished by increasingvertical spacing between applied load on hook 22 and fastener 6 inopening 46.

At least a portion of sides 34 may extend in a generally axialdirection. This generally axial portion 35 of sides 34 may extend alonga height of base 24, generally between opening 46 and bottom 38 ofthroat. Rear surface 32 of base 24 further may include one or morenotches 50 proximate upper ends of generally axial portions 35 forreceiving ears 74 (discussed below). Notches 50 may appear generallytriangular when viewing rear surface 32.

Turning to FIG. 2C, first portion 20 may include an angled face 90between front 30 and top 26. Angled face 90 may be angled from front 30by between about 25 degrees and about 40 degrees, preferably betweenabout 30 degrees and about 40 degrees, and in one embodiment, about 33degrees. In addition, angled face 90 may serve as a ramp for engagingsupport rib/cam member 84 on cover 60 and guiding and aligning cover 60as cover 60 is installed.

During mounting, anchor 4 is driven into substrate 2, and fastener 6 isinserted through opening 46 and into bore of anchor 4. Oftentimes, auser will not drive a fastener level such that when the head of thefastener contacts the recess, the first portion likely will not bemounted flush with substrate 2, leading to poor engagement between therear surface 32 and substrate 2.

It surprisingly was found that a raised lobe 52 protruding rearward fromrear surface 32 may alleviate this situation. Raised lobe 52 may extendbetween an upper surface that generally is aligned with top 26 alongarch 58 and a bottom 54 that may be generally normal to axis 8. Bottom54 further may be spaced from opening 46 so that when anchor 4 isinstalled in substrate 2 and first portion 20 is located so as to alignopening 46 with bore of anchor 4, there is a clearance between the headof anchor 4 and bottom 54. When fastener 6 is driven through opening 46,raised lobe 52 may contact substrate 2 first, causing first portion 20to bear against substrate 2 and not anchor 4, biasing or camming rearsurface 32 and slightly compressing bottom 28 against substrate 2.Preferably, lobe 52 is tall enough to cam bottom 28 of first portion 20against substrate 2 but not so tall that if the installer over-installsfastener 6, they will distort first portion 20 to the point where cover60 will not fit any longer.

Lobe 52 may have a thickness less than or equal to the thickness of base24 at a point just below bottom 54 of lobe 52, i.e., top 26 thatincludes lobe 52 may be about twice as thick as this lower portion.Preferably, lobe 52 may be between about 25% and about 100% of this basethickness, still more preferably between about 30% and about 50%.Alternatively, lobe 52 may be between about 10/1000″ thick and about1/10″ thick, preferably between about 50/1000″ and about 80/1000″.

In one embodiment, lobe 52 also may include a barb 92, as best seen inFIG. 2C. Barb 92 may be located on rear surface 55 of lobe 52, e.g.,proximate bottom 54 of lobe. Barb 92 may embed in or be compressed intothe surface of substrate 2 when first portion 20 is installed, therebyinhibiting both rotational and lateral movement of first portion 20relative to substrate 2. When first portion 20 is fully installed, barb92 may cooperate with tang or tangs (discussed below) to preventrotation of hook system 10. Alternatively, barb 92 particularly may beuseful in the event bottom 28 of first portion 20 is spaced away fromsubstrate 2 such that tangs are not engaged with substrate 2.

Barb 92 may only need to penetrate substrate 2 a small amount to providesufficient resistance. As such, barb 92 may be extend from lobe 52between about 5/1000″ and about 1/16″, preferably between about 10/1000″and about 1/32″. Barb 92 also may be about twice as tall as it is deep.In addition to providing rotational and lateral movement resistance, thesmall size of barb 92 may allow it to embed in a plurality of substratesof varying hardness, including friable materials such as drywall andmore rigid materials such as wooden hollow-core doors.

In addition to mounting misalignment, first portion 20 may deformslightly during installation. The upper lobe area initially may bear onsubstrate 2 as fastener 6 is installed. Tightening of fastener 6 againstrecess 48 may cause first portion 20 to bow slightly concavely orotherwise deform when viewed from the front. In order to minimize andcontrol the effects of any potential deformation, back 32 of firstportion 20 may include stopper pad 59 below fastener opening 46 toprovide a second surface rearward of back 32 to bear against substrate2. The degree of flexure or deformation may vary due to several factors,including the width, height and depth of the hook, the location ofopening 46 relative to lobe 52, the amount of force applied to firstportion 20 via fastener 6 during installation, and the degree ofmisalignment of the first portion and/or fastener 6. The combination ofupper lobe 52 and stopper pad 59 has been found to control thisdeformation and make it more predictable, leading ultimately to betterengagement of first portion 20 and cover 60.

Stopper pad may be formed when the first portion is created, e.g., itmay be cast or molded when the remainder of the first portion 20 is castor molded. The stopper pad 59 may be generally oblong and may extendsubstantially along a width of first portion, e.g., at least about halfthe width. Additionally, depth of stopper pad 59 from back 32 may taperfrom top of stopper pad 59 to bottom. Because first portion 20 may bowduring installation, this taper may allow stopper pad 59 to restgenerally flush against substrate 2.

In the embodiment shown in FIGS. 2A and 3A, top of stopper pad 59 mayextend between about 5/1000″ and about 50/1000″ from back 32, preferablybetween about 10/1000″ and about 30/1000″, and in one embodiment about12/1000″. In other embodiments, e.g., in larger hooks, top of stopper 59may extend about 17/1000″ or about 27/1000″. Because of taper, bottom ofstopper pad 59 may extend between about 4/1000″ and about 30/1000″,preferably between about 7/1000″ and about 25/1000″, and in oneembodiment, about 8/1000″. In other embodiments, e.g., in the largerhooks described above, bottom of stopper 59 may extend about 13/1000″ orabout 23/1000″. As set forth in each of these embodiments, stopper pad59 may taper about 4/1000″ from top to bottom.

Stopper pad 59 may be spaced from fastener opening 46 by a distancelarge enough to provide clearance for head of anchor 4 in case the headof anchor 4 is not installed flush against substrate 2. In oneembodiment, the distance between the center of fastener opening 46 andcenter of stopper pad 59 may be between about ⅛″ and about 1″,preferably between about ¼″ and about ½″, and in one embodiment about0.34″.

Rear surface 32 further may have at least one tang 56 aligned generallyaxially and protruding rearwardly. Tang 56 may be wedge-shaped, with abase having a thickness and coming to a point or line in order to allowtang 56 to be inserted into substrate 2. Tang 56 may cooperate withfastener 6 to provide two points of contact with substrate 2 so as toinhibit rotation of hook system 10. Although any two points on rearsurface 32 should work, tang 56 preferably may be located proximatebottom 28 and generally aligned with axis 8. Since bottom 28 of rearsurface 32 may be biased toward substrate 2 due to interaction of lobe52 with substrate 2 and, conversely, portions of rear surface 32 higherup may be spaced further away from substrate 2 than bottom 28, placingtang 56 higher on rear surface 32 may otherwise require tang 56 belonger in order to ensure that tang 56 embeds in substrate 2, requiringmore material to form first portion 20.

As seen in FIG. 5, first portion 20 may include a plurality of tangs 56,57. In this embodiment, tangs 56, 57 may be generally aligned and may begenerally equidistant from a centerline of first portion 20.Alternatively, tangs 56, 57 may have other configurations, e.g., beinggenerally aligned along centerline. Bases of tangs 56, 57 may be inrecess 96, which may have several benefits. For example, recess 96 meansless material is required to form first portion 20, reducing materialcosts. In addition, the depth of embedding of tangs 56, 57 may bedetermined by the hardness of substrate 2. As such, recess 96 may allowbases of tangs to be larger and, therefore, stronger, while minimizingthe amount of the tangs protruding beyond back 32 of first portion 20.For example, recess may be between about 10/1000″ deep and about 1/16″deep, preferably between about 20/1000″ and about 40/1000″, and in oneembodiment, about 30/1000″. In addition, tangs 56, 57 may have a heightfrom recess 96 of between about 10/1000″ and about ⅛″, preferablybetween about 1/32″ and about ⅛″, and in one embodiment, about 1/10″.

Turning to FIG. 6, an alternative embodiment may include alternativetangs 56′ and second tang 57′. As with the embodiment of FIG. 5, basesof tangs 56′, 57′ may be located in recess 96. However, in thisembodiment, alternative second tang 57′ may be significantly larger thantang 56′. Alternative second tang 57′ may be beneficial for embedding ina friable substrate such as drywall, but may be too large to embed in aharder substrate such as a hollow core door. In the latter case,alternative second tang 57′ may be frangible proximate its base and maybe broken off to allow first portion 20 to seat properly againstsubstrate 2. It is possible that alternative second tang 57′ may notbreak cleanly and, as such, recess 96 may allow any broken remnants toavoid sticking above back 32. Once alternative second tang 57′ isremoved, tang 56′ then may be embedded in the substrate 2. In thisembodiment, tang 56′ may have a height from recess 96 of between about10/1000″ and about ⅛″, preferably between about 1/32″ and about ⅛″, andin one embodiment, about 50/1000″. Alternative tang 57′ may have aheight from recess 96 of between about 1/16″ and about ¼″, preferablybetween about ⅛″ and about 3/16″, and in one embodiment, about 15/100″.Additionally, bases of tangs may have several shapes. For example, tangs56, 56′ and 57 both may have generally square bases, while alternativetang 57′ may be generally rectangular, having a height larger than awidth.

Turning now to FIG. 4, first portion 20 may include a cavity 98extending inward from recess 96. Cavity 98 may extend beyond front 30,e.g., to a point generally aligned with bottom of throat 38. Cavity 98may remove mass from first portion 20, making hook system 10 lighter andallowing system 10 to support an object with greater mass. In addition,less material needed to make first portion 20 due to cavity 98 maytranslate into lower material and manufacturing costs.

As seen in FIGS. 3A-3D., first portion 20 may include one or more femaledetents 31, 33 to enhance engagement of first portion 20 with cover 60by interfacing with male detents 81, 83 on cover 60. Alternatively,first portion 20 may include male detents and cover 60 may includefemale detents, or first portion 20 may include a combination of maleand female detents, with cover 60 including the respective female andmale detents. Detents 31, 33 may be located in groove 44, morespecifically as recessed portions of rear face 39 of second frontsurface 36. Detents 31, 33 may have a generally uniform depth relativeto rear face 39 or may taper from a deeper upper end to a shallowerlower end. Top of detents 31, 33 may include a stepped or rounded,convex surface transition from detent 31, 33 to rear face 39. Thissurface also may be a bearing surface for allowing male detents 81, 83to snap in place.

Cover

Returning to FIGS. 2A-2B, hook system 10 further may include a cover 60having a top 62, bottom 64, front 66, back 68 and outer side 70 andinner side 71. Outer side 70 may be substantially arcuate to form acontinuous surface from bottom 64 to top 62 and back to bottom 64. Inaddition, front 66 may include a notch 76 proximate top 62. Notch 76 maybe used to assist in removing cover 60 from first portion 20, e.g., byaccepting the tip of a screwdriver to which an upward force may beapplied. Cover 60 also may have a complementary support rib 84 on back68 and generally aligned with axis 8. Support rib 84 may add additionalstrength to cover 60 to avoid damage when a force is applied to notch 76and, as discussed above, to provide guidance along angled face 80 duringinstallation of cover 60.

As can be seen in FIGS. 2A, 3A, 7B, and 8B back 68 of cover 60 furthermay have features for guiding cover 60 onto, and keeping cover 60aligned with, first portion 20. For example, rear edge 61 may be angledinward an amount θ with respect to axis 8 or substrate 2 from top 62.Angle θ may be between about 1 degree and about 10 degrees, preferablybetween about 1 degree and about 5 degrees, still more preferablybetween about 1 degree and about 3 degrees, and in one embodiment about2 degrees. This angling may extend along rear edge 61 to a point betweenabout ⅓ and about ⅔ the height of cover from top 62, at which point rearedge 61 may extend generally aligned with axis 8 or may angle outwardaway from axis, until bottom 63 of rear edge, ending in taper 65 thatangles inward an amount β. Angle β may be between about 5 degrees andabout 15 degrees, preferably between about 7 degrees and about 11degrees, and in one embodiment, about 8 degrees. During installation,taper 65 may allow cover 60 slide along substrate 2 to aid in aligningcover 60 with first portion 20 without digging into substrate 2, as seenin FIG. 7A.

Turning to FIGS. 8A-8C, when cover 60 is in a fully installedconfiguration, angle θ may cause rear edge 61 to be spaced fromsubstrate, preventing rear edge 61 from scuffing or digging intosubstrate 2. If rear edge 61 angles back away from axis 8, bottom 63 ofrear edge may bear against or compress into the face of substrate 2.Substrate 2 may provide a spring action effect between the detents 31,33 on first portion and detents 81, 83 on cover by creating a resistiveforce pushing back against cover.

In addition, cover 60 may include a tongue, which may be divided intofirst tongue component 80 and second tongue component 82 thatoperatively engage groove 44 on first portion 20. Cover 60 may include aspace between first and second components 80, 82 to form a channel orrecess 72. In the event that the head of fastener 6 does not lay flushwith or below first front surface 30 but extends outward beyond firstfront surface 30, head of fastener 6 may pass through opening intorecess 72 when cover 60 is placed over first portion 20. Additionally,back 68 may include a second recess 73 within first recess 72 to provideeven greater clearance for head of fastener 6. Top of second recess 73may be generally arcuate and may align with top of top of fasteneropening recess 48 on first portion when cover 60 is installed.

Tongue on cover 60 may include male detents 81, 83, as best seen inFIGS. 1, 2A, and 2B. Detents 81, 83 may be spaced outward from first andsecond tongue components and are located so as to engage detents 31, 33on first portion 20 when cover 60 is installed. Upper portions ofdetents 81, 83 may extend outward from first and second tonguecomponents, and detents 81, 83 may taper toward first and second tonguecomponents along the length of detents 81, 83. As such, the outer edgesof detents 81, 83 may act as ramp surfaces to guide detents 81, 83 intoa secured position inside detents 31, 33. Upper portions of detents 81,83 may extend outward from first and second tongue components 80, 82 bybetween about 1/1000″ and about 10/1000″, preferably between about1/1000″ and about 5/1000″, and in one embodiment about 2/1000″.

Cover 60 may have a thickness less than thickness of base 24 of firstportion 20. Specifically, when installed, at least base 24 and raisedlobe 52 may bear against mounting substrate, but rear edge 61 of covermay be spaced from substrate, except for bottom 63, as best seen inFIGS. 8A and 8C. These figures also illustrate that, when installed,front 66 of cover 60 is preferably closer to substrate than second frontsurface 36 of first portion 20. This slight indentation or recess ofcover 60 relative to second front surface 36 may prevent snagging oraccidental dislodgement of cover 60 when removing an object from hook22.

Cover 60 additionally may include one or more ears 74 proximate top 62of back 68. Ears 74 may be substantially symmetrically located onopposite sides of axis 8. In addition, ears 74 may be shapedsubstantially similarly to, or may be smaller than, notches 50 on firstportion 20 to allow ears 74 to operatively engage notches 50 when cover60 is placed on first portion 20. For example, as seen in FIG. 2A, ears74 are generally triangular and match the generally triangular shape ofnotches 50.

Staying with FIG. 2A, cover 60 further may have one or more guides 78 oneach side of axis 8 for interfacing with generally axial portions 35 onfirst portion 20. Preferably, cover 60 has a plurality of guides 78,still more preferably about three guides 78, on each side of axis 8. Inorder to interface with generally axial portions 35, outer ends ofguides 78 preferably are spaced substantially equidistantly from axis 8.

One or both of first portion 20 and cover 60 may receive a finishingtreatment such as plating or painting/powder coating. These treatmentsadd thickness to the surfaces on which they are applied, e.g., betweenabout 1/1000″ and about 2/1000″ for plating and between about 3/1000″and about 6/1000″ for powder coating. The dimensions described above mayrepresent raw distances or clearances, which may be altered slightly bythese finishing treatments. Preferably, however, both the first portion20 and cover 60 receive the same finishing treatment, so that relativedimensions between these elements may remain generally uniform afterfinishing. In addition, because plating or painting may build up thedetent members, thereby decreasing the amount of interference fit,similar finishing on both the first portion and cover may result in therelative location of the detents remaining generally constant. In thiscase, even the reduced interference fit may still suffice to createpositive engagement between the detent members and, by extension,between the first portion and the base.

Anchor

Hook system 10 further may include a drywall anchor 4. Various types ofanchors may be used with system 10, for example, anchors sold under thetrademarks E-Z ANCOR, STUD SOLVER, MINI STUD SOLVER, TWIST-N-LOCK orTAP-N-LOCK, see commonly assigned U.S. Pat. No. 4,601,625 and U.S.patent application Ser. Nos. 10/844,706, 11/832,311 and 12/167,742 toErnst, et al., the contents of which are incorporated herein byreference. Anchor 4 may be a self-drilling drywall anchor capable ofpenetrating studs, and may have the configuration shown in FIGS. 15-16.

For example, anchor 4 may having an elongated body 312 with an axis 306,an axial bore 308 adapted to receive an elongated mounting fastener 4, aflared end 314 having torque transmitting surfaces 315 therein, aproximal portion 318 proximate flared end 314, an intermediate portion320, a distal portion 322, and a drilling tip 316 generally oppositeflared end 314, wherein proximal portion 318 has a threaded exterior,such as drywall gripping threading 319, having a root 326, a crest 327with a crest diameter DC, and a thread height DH, intermediate portion320 has a threaded exterior, such as member gripping threading 321,having a root 328, a crest 329 with a crest diameter MC substantiallysmaller than drywall gripping threading crest diameter DC, and a threadheight MH substantially smaller than drywall gripping thread height DH,and distal portion 322 has a threaded exterior, such as drillingthreading 323, having a root 330 that tapers toward drilling tip 316, acrest 331 with a crest diameter TC substantially smaller than drywallgripping threading crest diameter DC, and a thread height THsubstantially smaller than drywall gripping thread height DH.

In addition, anchor 4 may include splines 344 in bore 308 of anchor 4for engaging with mounting fastener 6. Mounting fastener threading 405taps mating threads 345 into splines 344 so that mounting fastener 6 isthreadingly engaged with splines 344, and hence with anchor 4. Splines344 also add structural support to anchor 4 so that body 312 of anchor 4can withstand higher torsion forces when driven through drywall 2 andsupport member 5. Splines 344 may extend along a length of bore 308 andmay preferably extend substantially along the entire length of bore 308.

Anchor 4 further may have an additional, tertiary thread 390 proximateflared end 314. Additional thread 390 may have a terminal end 391circumferentially spaced from a terminal end 317 of proximal portionthreading 319. Additional thread 390 further may have a leading end 392generally circumferentially aligned with a terminal end 317 of proximalportion. Preferably, terminal end 391 of additional thread 390 may beoffset from terminal end 317 of proximal portion threading 319 bybetween about 120 and about 240 degrees, preferably between about 150and about 210 degrees, still more preferably about 180 degrees.

Offsetting additional thread 390 from proximal portion threading 319means that a plurality of threads may be engaged in the substrate 2 whenanchor is fully installed. Moreover, offsetting of threads may causeproximal portion threading 319 and additional thread 390 to be generallydiametrically opposed such that, when installed, there is at least onediameter at which threads of anchor 4 engage substrate 2 on both sidesof anchor 4, resulting in a more even distribution of force duringloading and a stronger, more stable engagement of anchor 4. Withoutadditional thread 390, when anchor 4 is installed in a thin substratesuch as the face of a hollow core door, proximal portion threading 319may either not engage face or may only engage face on one side of anchor4, resulting in a weaker, less stable engagement and, subsequently, alower holding strength.

The substrate 2 may be a friable material chosen from one of severalfriable materials used in construction. An example of the friablematerial is gypsum based drywall, such as the gypsum drywall sold underthe trademark SHEETROCK by United States Gypsum. Drywall typically has athickness T of ½ inch or ⅝ inch, but it can be obtained in otherthicknesses, such as ⅜ inch.

Typically, friable materials such as drywall are mounted to a member,such as a wood structural support member, plywood, or another friablematerial, such as another layer of drywall. The member can be a supportmember, such as a wood support member, for example a 2×4 stud or thelike, evenly spaced from other wood studs, e.g. every 16 inches, or ametal support member, such as a steel support stud. Support members aresubstantially more resistant to pullout than drywall because they aremuch less likely to break apart.

Alternatively, the substrate 2 may be a semi-rigid material. Forexample, it may be a thin piece of solid wood, fiberboard, plywood, ormultiple materials having a veneer coating and may be, e.g., one side ofa hollow core door. The semi-rigid material may come in a variety ofthicknesses, but generally may be between about 1/16 inch and about ⅛inch.

Fastener

Mounting fastener 6 is preferably a threaded fastener, such as amounting screw, having an elongate shank 434 with a head 435 at one endand a tip 436 at the other. Shank 434 of mounting fastener 6 includesthreading 405 which engages with interior bore 308 of anchor 4.Threading 405 of mounting fastener 6 can be of a standardized threadform, such as Unified Coarse (UNC) or Unified Fine (UNF) threading, orthreading 405 can be of a specialized thread form. Mounting fastener 6can be a standard #6, #7 or #8 UNC screw, wherein head 435 has aPhillips recess, and a total elongate length FL of between about ½ inchinches and about 2 inches or more, preferably about 1¼ inches. Mountingfastener 6 can have a thread density of between about 8 threads per inchand about 18 threads per inch, preferably about 15 threads per inch.

Various Sizes of First Portion and Cover

Hook system 10 may come in variety of sizes for multiple applications,e.g., small, medium and large sizes. Each variation may employ asimilarly sized anchor 4 and fastener 6 but may have differently sizedfirst portions 20 and covers 60. For example, a “small” first portion 20may have a width between generally axial sides 35 of between about ½″and about 1″, preferably between about ⅝″ and about ⅞″, still morepreferably about ¾″, and in one embodiment about 0.745″. First portion20 also may have a height between about 2″ and about 3″, preferablybetween about 2¼″ and about 2¾″, still more preferably about 2½″, and inone embodiment, about 2.43″. In addition, first portion may have amaximum throat width, T, of between about ⅜″ and about 1″, preferablybetween about ½″ and about ¾″, and in one embodiment about 0.52″.Moreover, first portion may have a thickness from first front surface 30to rear surface 32 of between about 1/16″ and about 3/16″, preferablybetween about 1/16″ and about ⅛″, and in one embodiment about 0.1″ andfurther may have a thickness between first front surface 30 and rearsurface of lobe 52 of between 3/32″ and about ¼″, preferably betweenabout ⅛″ and about 3/16″, and in one embodiment about 0.157″.Additionally, tang 56 may have a depth of between about 1/16″ and about3/16″, preferably between about 1/16″ and about ⅛″, and in oneembodiment about 0.92″.

A “medium” version of system 10, may include first portion 20 having awidth between generally axial sides 35 of between about ¾″ and about1½″, preferably between about ⅞″ and about 1¼″, still more preferablyabout 1″, and in one embodiment about 1.076″. First portion 20 also mayhave a height between about 2½″ and about 3½″, preferably between about3″ and about 3¼″, still more preferably about 3⅛″, and in oneembodiment, about 3.18″. In addition, first portion may have a maximumthroat width, T, of between about ¾″ and about 1½″, preferably betweenabout ⅞″ and about 1⅛″, and in one embodiment about 1.01″. Moreover,similar to the “small” version, first portion 20 may have a thicknessfrom first front surface 30 to rear surface 32 of between about 1/16″and about 3/16″, preferably between about 1/16″ and about ⅛″, and in oneembodiment about 0.1″. First portion 20 further may have a thicknessbetween first front surface 30 and rear surface of lobe 52 of between3/32″ and about ¼″, preferably between about ⅛″ and about 3/16″, and inone embodiment about 0.164″. Additionally, tang 56 may have a depth ofbetween about 1/16″ and about 3/16″, preferably between about 1/16″ andabout ⅛″, and in one embodiment about 0.92″.

A “large” version of system 10 may include first portion 20 having awidth between generally axial sides 35 of between about 1″ and about1¾″, preferably between about 1¼″ and about 1½″, still more preferablyabout 1 5/16″, and in one embodiment about 1.318″. First portion 20 alsomay have a height between about 3½″ and about 4½″, preferably betweenabout 3¾″ and about 4¼″, still more preferably about 4″, and in oneembodiment, about 3.93″. In addition, first portion 20 may have amaximum throat width, T, of between about 1¼″ and about 2″, preferablybetween about 1½″ and about 1¾″, and in one embodiment about 1.62″.Moreover, similar to the “small” and “medium” versions, first portion 20may have a thickness from first front surface 30 to rear surface 32 ofbetween about 1/16″ and about 3/16″, preferably between about 1/16″ andabout ⅛″, and in one embodiment about 0.1″. First portion 20 further mayhave a thickness between first front surface 30 and rear surface of lobe52 of between 3/32″ and about ¼″, preferably between about ⅛″ and about3/16″, and in one embodiment about 0.183″. Additionally, tang 56 mayhave a depth of between about 1/16″ and about 3/16″, preferably betweenabout 1/16″ and about ⅛″, and in one embodiment about 0.92″.

Single-bodied hooks that rely on an adhesive backing for engagement witha substrate such as drywall also may be produced in a variety of sizes.For small, medium and large versions of these hooks, holding strengthsof about 1 lb., about 3 lb. and about 5 lb., respectively, have beenclaimed. While sizing of these hooks may not align identically with thevarious sizes of hook system 10 described above—e.g., a “large”adhesive-backed hook may be relatively comparable in size to the“medium” hook described above, each of the small, medium and large hooksof the present invention may have a holding strength of about 100 lbs.,or significantly higher than the strength of the adhesive-backed hooks.In addition, the components of system 10, including first portion 20 andcover 60 may be fabricated in a variety of ways, including using diecast zinc or a zinc alloy such as Zamak 1 or 3 or injection moldedplastic. Additionally or alternatively, first portion 20 may include anadhesive backing on rear surface 32 to support first portion 20 andcover 60 against substrate 2.

Second Embodiment

Turning to FIGS. 9-11, a second embodiment of hook system 110 is shown.Elements common to the first embodiment share the same referencenumerals but include a 100s prefix.

Like the first embodiment, system 110 may comprise a first portion 120,a cover 160, an anchor 4 and a fastener 6 and may have features similarto those described above. Cover 160 may be substantially similar tocover 60, including male detents 181, 183 on respective tonguecomponents 180, 182, recess 172 in back 168, a plurality of ears 174disposed on opposite sides on axis 8, a plurality of guides 178 alsodisposed on opposite sides of axis 8 and having ends generallyvertically aligned, and tapers 165 proximate bottoms 163 of rear edge161. Cover 160 also may have an angled rear edge 161 with angles similarto those described for the first embodiment above, such that most ofrear edge 161 may be spaced from substrate when installed, with bottoms163 bearing against substrate. First portion 120 may include a stopperpad 159, a raised lobe 152 with barb 192, tangs 156, 157 in recess 196on back of base 124, channel 198 in recess 196, and female detents 131,133 on rear face 139 of second front surface 136.

As can be seen in FIG. 9, first portion 120 may include a plurality ofhooks 122, 123 extending from bottom 128 of base 124. Hooks 122, 123 mayextend away from base 124 at substantially symmetrical angles withrespect to axial plane 108 so as to provide hooks for hanging multiplearticles or to provide increased surface area to hang a larger orbulkier item such as a robe, e.g. Portions of hooks 122, 123 proximatebottom 128 of base 124 may be narrower than similar portions in thefirst embodiment so as to make room for both hooks. However, due totheir separation from each other, and in order to support larger items,bulbs 140, 141 of hooks 122, 123 may be larger than bulb 40, i.e.,generally semicircular but with a larger diameter.

Third Embodiment

Turning now to FIGS. 12-14, a third embodiment of the hook system isshown. As with the second embodiment, elements common to the firstembodiment share the same reference numerals but here include a 200sprefix.

In this embodiment, hook system 210, like system 110, may include afirst portion 220, a cover 260, an anchor 4 and a plurality of fasteners6 and may have features similar to those described above. First portion220 may include a stopper pad 259, a raised lobe 252 with barb 292,tangs 256, 257 in recess 296 on back of base 224, channel 298 in recess296, and female detents 231, 233 on rear face 239 of second frontsurface 236.

Cover 260 may include male detents 281, 283 on respective tonguecomponents 280, 282, recess 272 in back 268, a plurality of ears 274disposed on opposite sides on axis 8, a plurality of guides 278 alsodisposed on opposite sides of axis 8 and having ends generallyvertically aligned, and tapers 265 proximate bottoms 263 of rear edge261. Cover 260 also may have an angled rear edge 261 with angles similarto those described for the first embodiment above, such that most ofrear edge 261 may be spaced from substrate when installed, with bottoms263 bearing against substrate.

Unlike the second embodiment, instead of projecting outwardly andupwardly from base 224 at bottom 228, hook 222 of the third embodimentmay extend downwardly and outwardly from base 224, before turning upwardto a distal end 239 having a bulb or knob 240. Knob 240 may extendvertically to a point higher than end of hook 222 proximate base 224 tohold objects on hook 222 without sliding off but alternatively mayextend higher or lower.

In this embodiment, a plurality of interchangeable covers 260 may besupplied, which may provide system 210 with greater functionality. Forexample, a first cover that is similar in shape to covers 60, 160, i.e.,substantially unadorned may be applied. In this configuration, system210 may be particularly well suited to serve as a key holder or hathook. Alternatively, system 210 may include a second cover 260′ similarto cover 60 but with an additional hook 223 extending therefrom. Hook223 may be generally axially aligned and extend outward and/or upwardfrom cover 260′ to a distal end extending beyond distal end of hook 222.As such, system 210 may allow for the hanging of multiple objects, e.g.,as both a key holder and a wardrobe hook system.

Each of the embodiments described above may include additional openingsfor receiving other fasteners. In addition, the back of each firstportion may be generally planar, i.e., without one or more of the tangs,stopper pad and/or raised lobe, although the backs still may includenotches for receiving ears on the cover.

Modifications to the third embodiment may be seen in FIGS. 21-23.Turning to FIG. 21, base 220 may include a second fastener opening 247to complement first fastener opening 246. First opening 246 may bedisposed proximate a top 226 of base, e.g., at a location substantiallylevel with ears 274 of cover 260 when cover 260′ is installed. Secondopening 247 may be more centrally located along a height of base 220,e.g., generally aligned with a bottom of notches 250.

Cover 260′ with additional hook 223 may benefit from a tighter, moreconsistent fit with base 220, which may be achieved in one or moremanners. For example, notches 250′ may be less deep than in the otherembodiments shown in the figures, i.e., base 220 may be thicker in notchregion, which may allow cover 260′ to more securely contact frontsurface 236 of base and may allow ears 274 to contact more of notches250′.

Notches 250′ also may be longer than notches 250 shown in FIG. 14. Asseen in FIG. 21, e.g., notches 250′ may be between about ⅕ and about ⅔ aheight of back portion 232 of base 220, preferably between about ¼ andabout ½, and in one embodiment, about ⅓ the height. As such, base 220may be able to support and withstand higher cantilevered forces appliedby article supported by additional hook 223.

Notches 250′ also may include a plurality of notch surfaces such asfirst notch surface 251 and second notch surface 253. First notchsurface 251 may be generally parallel to front surface 236 and/or back232 of base 220 and may be disposed closer to back 232 than second notchsurface 253, which also may be generally parallel to front surface 236and/or back 232. First notch surface 251 may be substantially longerthan second notch surface 253, e.g., first surface 251 may be about 80%and second surface about 20% of a total length of notch 250′. Due todiffering heights, there also may be a step down from first surface 251to second surface 253. Step may be generally perpendicular to one orboth of surfaces 251, 253 but preferably is inclined with respect toboth surfaces, forming a ramp-like surface.

In addition, notch 250′ may follow a generally linear or planar pathalong its length, having a side surface 267 that is generally vertical,although side surface also may taper outwards from top to bottom.Staying with FIG. 21, notch 250′ also may include an inset portion 249at an upper end that may extend inwards from second notch surface 253towards plane of symmetry 208. Turning to FIG. 23, like the rest ofnotch 250, inset portion 249 may have an inner side surface 267′ that isgenerally vertical and may be generally perpendicular to one or both ofa primary surface of inset portion 249 and back 268. Inset portion 249also may have a bottom side surface 267″ that may be angled downwardsand outwards, with inner side and bottom side have substantially similarlengths.

Increased length of notch 250′ may affect configuration of sides 234 ofbase 220, particularly generally axial portion 235 of sides 234.Generally axial portion 235 may include a first portion 235′ extendingat a greater width than the rest of the generally axial portion. As seenin FIG. 21, first portion 235′ may extend between a bottom of notch 250′and protrusions 221. Conversely, generally axial portion 235 may includea second portion 235″ that may extend at a narrower width than firstportion 235′. Second portion 235″ may extend alongside notch 250′ andmay have a common edge with notch 250′. As such, base 220 with aplurality of notch surfaces 251, 253 may therefore be employed with avariety of different covers having different ear patterns.

Cover 260′ similarly may be reconfigured to account for modifications tobase 220. Turning to FIG. 22, increased length of notch 250′ may allowfor longer ears 274′. Ears 274′ may be configured to operatively engagenotch 250′, i.e., a thickness of ears 274′ may be modified to accountfor reduced depth of notch 250′ at first surface 251. Preferably,however, thickness of ears 274′ may remain unchanged, which may create atighter interface with the thicker portion of notch 250′ at firstsurface 251. This tighter interface may be useful in all applications,although it may have particular benefits with cover 260′ includes one ormore hooks 223, such that cover 260′ may remain stationary even whensubjected to repeated loading and unloading forces.

Ears 274′ may have an inner edge configured to align with and engageside surface 267 on base 220. Spacing between ears 274′ may besubstantially similar to distance between side surfaces 267, althoughspacing may be slightly greater to allow for clearance or slightlysmaller to create a slight interference fit and a tighter connection.

Staying with FIG. 22, ears 274′ also may include a tab or portion 277configured to fit into inset portion 249 of notch 250′, e.g., portion277 may be shaped similar to inset portion 249, including having agenerally vertical side portion and a bottom portion that may betapered.

Guides 278 also may be modified to account for changes to base 220. Asseen in FIG. 22, e.g., ears 274′ preferably may extend at least as lowas a first guide 278′ and may be formed in a generally unitary fashionwith the first guide, such that a bottom of ear 274′ may be generallyaligned with bottom of first guide 278′. This relationship between ear274′ and first guide 278′ may provide additional structural support tothe ear 274′. Turning to FIG. 23, additionally or alternatively, atleast one guide 278″ may be shortened and extend inward a lesser amountthan the other guides to allow for increased width of the first portion235′ of generally axial portion 235.

When cover 260 is installed on base 220, preferably at least a portionof ear 274 or 274′ extends downward a sufficient distance to bypasssecond notch surface 253 and rest on or otherwise engage first notchsurface 251, which may allow for tighter engagement between base 220 andcover 260 and reduce rattle between pieces. Alternatively, with shorterear 274, preferably substantially all of ear 274 rides in second notchsurface 253. To remove this cover 260′, the EZ Open procedures discussedbelow may be used, which may include tilting a lower portion of cover260′ away from base 220 before or at the same time as lifting cover 260′upwards. As the cover is lifted, ear 274 may slide into second notchsurface 253, providing additional clearance for cover 260 to pivot.

Alternatively, if cover 260′ includes a longer ear 274′, such as in FIG.22, cover 260′ may be removed by lifting substantially verticallywithout tilting cover 260′. Because cover 260′ with longer ear 274′likely also may include additional hook 223, this additional hook 223may be grasped to pull cover 260′ away from base 220.

Fourth Embodiment

Turning now to FIGS. 17-20, a further embodiment is shown. Elements maybe similar to those of the previous embodiments, although elements inthis embodiment have a 500s prefix and may be discussed in greaterdetail below. Although these figures show a single-leg hook and a basewith side-by-side tangs, additional hook or tang configurations,including but not limited to the various configurations described in theembodiments above, are within the scope of this embodiment.

In this embodiment, second front surface 536 of base 520 may besubstantially smaller than in previous embodiments, although base 520still may include groove 544 between first and second front surfaces530, 536. For example, whereas the groove in previous embodiments mayhave extended to a height higher than the top of the hook, in thisembodiment, groove 544 may have a low point at its external edgesproximate sides 534 that may be generally axially aligned with top ofcavity 598, and an apex generally aligned with top of recess 596.

Cover 560 may include an inner side 571 similarly shaped to top 537 ofsecond front surface 536 so that, as with the previous embodiments,inner side 571 and top 537 may align to form a generally continuoussurface, although cover 560 may be recessed slightly from second frontsurface 536. In this embodiment, first and second tongue components 580,582 may extend downward from back 568, so as to resemble tabs extendingdownward behind inner side 571 when viewing cover 560 from the front566. Tongue components 580, 582 may be the distal ends of railsextending substantially the height of cover 560. Rails may have agenerally rectangular cross-section. Preferably, however, rails mayinclude a channel extending inward from back 568 so as to give channelsa U-shaped cross-section. Removing material to form the channel mayreduce the weight of cover 560 and the amount of material necessary tomold cover 560 and also may allow material flow and limit cooling issuesor sink by avoiding a thick area of material.

Tongue components 580, 582 may be separated a distance sufficient topermit passage of fastener head 435 between them when cover 560 is beingcoupled to base 520. Tongue components 580, 582 preferably extenddownward from inner side 571 by a distance generally equal to, orslightly less than, a depth of groove 544.

In this embodiment, stopper or shim pad 559 on back 532 of base portion520 may be spaced proximate to fastener opening 546. Because anchor 4includes bore 308 sized to receive fastener 6, flared end 314 of anchor4 preferably has a larger diameter than bore 308 and, therefore, offastener opening 546. As such, while still allowing for biasing of baseportion 520 as described above with respect to other embodiments, pad559 may bear against flared end 314 to eliminate any gap between flaredend 314 and base portion 520. By keeping anchor 4 engaged firmly betweensubstrate 2 and base portion 520, pad 559 may assist in preventing“jacking” of anchor 4 away from substrate 2 when fastener 6 istightened, which may weaken connection between anchor 4 and substrate 2.

Turning now to FIGS. 17 and 18, system 510 may include furtherengagement structure to assist in holding base 520 and cover 560together. For example, base 520 may include one or more bumps orprotrusions 521 and one or more valleys or indentations 523 forinterfacing with one or more respective valleys or indentations 575 andbumps or protrusions 579, respectively. System 510 may include aplurality of these respective protrusions and indentations, which mayincrease the connection between base 520 and cover 560 and may make thatconnection better balanced, e.g., by locating a protrusion andindentation on generally opposite sides of plane of symmetry 8 fromanother protrusion and indentation.

Staying with FIG. 18, protrusion 521 and indentation 523 on base 520 maybe on sides 534 or, more specifically along generally axial portions535, proximate bottom 528. Protrusion 521 may extend downward andoutward from generally axial portion 535, and indentation 523 may extenddownward and inward from protrusion. Both protrusion 521 and indentation523 may include curved ramp surfaces to allow for sliding engagementwith protrusion 579 and indentation 575 on cover 560. In addition, upperand lower ends of indentation 523 may extend outward substantially thesame distance from plane of symmetry 8, although indentation 523 itselfmay not be generally symmetrical. Instead, in one embodiment, slope ofindentation 523 from upper end to nadir may be steeper than slope fromlower end to nadir. While still allowing for sliding engagement betweenbase 520 and cover 560, this steeper slope may increase frictionalforces necessary to separate base 520 and cover 560, resulting in betterengagement. Interference or overlap between protrusions 521, 579preferably may be between about 0.002″ and about 0.006″ so that theprotrusions may encounter each other prior to the locked or unlockedpositions while still allowing passage of protrusion 579 past protrusion521.

Similarly, protrusion 579 and indentation 575 on cover 560 may be formedproximate bottom 563 of rear edge 561. Protrusion 579 may extend upwardand inward, i.e., toward axis of symmetry 8, from bottom 563, andindentation 575 may extend upward and outward, i.e., away from axis ofsymmetry 8, from protrusion 579. As with indentation 523 on base portion520, indentation 575 on cover 560 may have its steepest slope proximateprotrusion 579.

During installation, cover 560 may slide along generally axial portions35 of base portion 520 until protrusion 579 encounters protrusion 521.Protrusions may be sized so as to increase frictional engagement betweeneach other, but may not be so large as to inhibit sliding protrusion 579past protrusion 521. With the application of additional force,protrusion 579 extends beyond protrusion 521 to settle into indentation523, while protrusion 521 similarly settles into indentation 575.Reversing the direction of force reverses the process, causingprotrusions 521, 579 to switch positions, uncoupling base 520 and cover560.

EZ Open Features

Turning now to the section view of FIG. 25 and the detail view of FIG.25A, holder may include features that assist in separating cover 560from base 520. It may be desirable to remove cover 560 from base 520 bylifting cover 560 both upwards and away from base at the same time. Assuch, interfacing components of base 520 and cover 560 may includeelements facilitating motion in these directions.

For example, groove 544 in base may be configured to receive one or moretongue components 580, 582 extending from cover. Each tongue componentmay include a forward face 585 angled downward, such that tonguecomponents 580, 582 may be thicker at the top than at the bottom.Similarly, groove 544 may include a rearward facing, angled, forwardface 594 that also may be angled downward. In one embodiment, faces 585,594 of cover and base may be angled substantially the same amount, e.g.,between about 120 degrees and about 140 degrees. As such, face 594 ofbase may form a ramp surface along which face 585 may translate whencover 560 is removed.

Because angled faces may permit easier motion between base and cover,one or both of base and cover may include a stop or other means forretaining cover 560 in a resting position with respect to base 520 andto prevent accidental dislodgement of cover 560. Retaining means mayinclude a cessation of angled faces 585, 594 or a change in the angle offaces 585, 594. As seen in FIG. 25A, this change may result in theformation of a step 586 on cover and/or a step 593 on base. Steps 586,593 may be generally mirror-images of one another, e.g., step 586 mayprotrude outward from cover 560 while step 593 may extend inward intobase 520, although the opposite also is possible.

Angled face 585 and step 586 of cover 560 may be disposed across partand preferably an entire width of tongue component 580 (with similarelements on tongue component 582). Similarly, angled face 594 and step593 of base 520 may be disposed against an entire width of groove 544,although, at a minimum, face and step preferably overlie at least areasin communication with tongue components 580, 582 when base 520 iscoupled to cover 560.

Steps 586, 593 may be substantially similarly sized and shaped toincrease interfacing between base 520 and cover 560. Alternatively,while steps 586, 594 may be similarly shaped, step 586 may be sized tocreate clearance with respect to base 520. For example, step 586 oncover may be shallower than step 593 on base, which may permit a largeramount of cover 560 to interface with base 520. Conversely, step 586 mayextend laterally a greater amount than step 593, which may help ensurethat cover 560 interfaces more securely between first front surface 530and second front surface 536 of base 520.

Steps 586, 593 may have a height between about 25% and about 75% that ofgroove 544, preferably between about 40% and about 60% the height.Additionally, while only a single step is shown, system 510 may includeadditional retaining means, e.g., additional steps.

Step 586 also may include a radiused edge 587, which may assist inremoving tongue components 580, 582 from groove 544 proximate top 537 ofsecond front surface 536.

Once coupled to base 520, cover may be removed by lifting straight up,causing tongue components 580, 582 to become unseated from withingroove. Preferably, however, a user may engage cover, e.g., on outerside 570 proximate bottom 564. Cover 560 then may be lifted upwardswhile bottom 564 is pulled forwards, towards hook 522. During thisprocess, angled face 585 of cover may slide along angled face 594 ofbase and/or front face of cover step 586 may translate against orrelative to front face of base step 593. As radiused edge 587 clears top537 of second front surface 536, cover 560 may be sufficiently loosenedthat it may be disengaged and separated easily from base 520.

When base 520 and cover 560 are coupled, detents 531, 581 are engagedwith one another, as seen in FIG. 18. By pulling cover 560 forwardinstead of solely upward, detents may be separated by minimizing oreliminating the time when they are in an interference relationship withone another. Separation between detents 531, 581 may be assisted viataper 565 on cover 560. Taper 565 may cut the corner between back 568and inner side 571 of cover. Taper may extend substantially along alength of detent 581 and may be thicker proximate the upper end ofdetent 581 than its lower end. Because detents 531, 581 may beresponsible for a significant portion of engagement between base andcover, allowing detents 531, 581 to bypass one another more quickly maylead to faster, easier separation of base and cover.

Once tongue components 580, 582 are removed from within groove, ears 574on cover 560 may remain at least partially engaged with notches 550 onbase 520. Completing separation of cover 560 from base 520 then mayinclude lifting cover 560 upwards until ears 574 clear notches 550.

Method of Use

Each of the holder systems 10, 110, 210, and 510 may be used by a methodincluding the steps of selecting a location on a substrate 2, drivinganchor 4 into substrate 2 and, if present, into support behind substrate2, positioning the holder against the wall or ceiling at the selectedposition such that tang or tangs and barb 92 initially may indentsurface of substrate 2 and such that opening 46 is substantially alignedwith bore of anchor 4, aligning fastener 6 with opening 46, insertingfastener 6 through opening 46 and into bore, rotating fastener 6 in aclockwise direction so that fastener 6 engages anchor 4, pressing on thefirst portion 20 to cause the rearwardly projecting tang 56, if present,to puncture the surface of the substrate 2 and extend a short distanceinto the substrate 2 and so that first portion 20 may deform, causingone or more of the raised lobe 52 and stopper pad 59 to contactsubstrate 2, and continuing to rotate fastener 6 until fastener headengages recess 48 and first portion 20 is fastened securely and,preferably, rotationally fixedly, to substrate 2.

In addition, the method may include aligning cover 60 with first portion20, sliding tapers 65 of cover 60 along substrate, and sliding cover 60onto first portion to cover or disguise the appearance of fastener(s) 6,so that first and second tongue components 80, 82 operatively engagegroove 44, ears 74 operatively engage notches 50, guides 78 operativelyengage generally axial sides 35, and/or male detents 81, 83 operativelyengage female detents 31, 33.

When the cover 60 is installed on first portion 20, cam member 84 oncover 60 may bear on top 26 of first portion 20. The tapers 65 proximatebottom 63 of rear edge 61 may bear on the face of the substrate 2. Inbetween these bearing points, the male detents 81, 83 may engage thefemale detents 31, 33. The surfaces bearing against one another maycreate a snap fit or spring action between first portion 20 and cover 60to create positive retention of cover 60.

While the foregoing written description of the invention enables one ofordinary skill to make and use what is considered presently to be thebest mode thereof, those of ordinary skill will understand andappreciate the existence of variations, combinations, and equivalents ofthe specific exemplary embodiments and method herein. The inventionshould therefore not be limited by the above described embodiments andmethod, but by all embodiments and methods within the scope and spiritof the invention as claimed.

1. A substrate-mountable holder system, comprising: a first portioncomprising a base having an opening for receiving a fastener to mountthe base to a substrate, a hook, a first front surface and a secondfront surface with a groove therebetween, wherein the groove includes arearward facing face having a step; and a second portion for operativelyengaging the first portion, the second portion including a tonguecomponent positionable within the groove, wherein the tongue componentincludes a forward facing face having a step.
 2. A holder systemaccording to claim 1, wherein the groove includes a ramp surface betweenthe step on the first portion and a bottom of the groove.
 3. A holdersystem according to claim 1, wherein the tongue component includes anangled face between the step on the second portion and a bottom of thetongue component.
 4. A holder system according to claim 1, wherein thestep on the second portion includes a radiused edge.
 5. A holder systemaccording to claim 1, wherein the step on the second portion has ahorizontal length greater than a horizontal length of the step on thefirst portion.
 6. A holder system according to claim 1, wherein the stepon the first portion has a height generally equal to a height of thestep on the second portion.
 7. A holder system according to claim 1, thesecond portion comprising an ear and the first portion comprising anotch configured to receive the ear.
 8. A holder system according toclaim 7, wherein the notch extends downward from a top of the firstportion.
 9. A holder system according to claim 7, wherein the notch hasa height such that the ear remains disposed within the notch after thetongue component clears the rearward facing face of the groove.
 10. Aholder system according to claim 7, wherein the notch has a first notchsurface at a first depth relative to a back of the base and a secondnotch surface at a second, deeper depth relative to the back.
 11. Asubstrate mountable holder system, comprising: a base having a firstfront surface and a second front surface, a rear surface, a top and abottom, an opening for receiving a fastener, a hook extending fromproximate the bottom, and a channel between the first and second frontsurfaces; the base further including at least one notch extending inwardfrom the rear surface, the notch having a first surface at a first depthrelative to a rear surface of the base and a second surface at a second,deeper depth relative to the rear surface; and a cover having at leastone ear for releasably engaging the at least one notch.
 12. A holdersystem according to claim 11, further comprising a plurality of openingsfor receiving a plurality of fasteners.
 13. A holder system according toclaim 11, the cover further comprising a plurality of guides extendinginward from a side of the cover.
 14. A holder system according to claim13, wherein one of the guides forms a lower portion of one of the atleast one ears.
 15. A holder system according to claim 13, wherein thebase has a first width along the at least one notch and a second, widerwidth below the at least one notch; and further wherein at least one ofthe guides extends inward a smaller amount than another one of theguides to accommodate the second, wider width of the base.
 16. A holdersystem according to claim 11, wherein when the cover is coupled to thebase, at least a portion of the ear is disposed along the first surfaceof the notch.
 17. A holder system according to claim 11, the covercomprising: a hook extending away from a front surface; wherein the atleast one ear extends between about ⅓ and about ½ the height of thecover.
 18. A holder system according to claim 11, the notch furthercomprising an inset portion proximate the top, the inset portionextending inwards from the second surface and having a depthsubstantially equal to the first surface.
 19. A holder system accordingto claim 18, the at least one ear configured to be received in the notchat substantially all of the inset portion and a majority of the firstsurface.
 20. A holder system according to claim 18, wherein at least oneof the base and cover is substantially symmetrical.